Adapter for wire dispensing carton

ABSTRACT

An adapter for inserting into a carton containing a non-reel coil of filamentary material or wire has a shaft-receiving sleeve supported by a box structure. The adapter&#39;s box structure has top and back walls joined at right angles and reinforced by side walls. Knobs extend outwardly from the side walls and have openings therethrough. Ribs on the underside of the top wall define a channel which is aligned with the openings in the knobs. The ribs, top wall and knobs define a sleeve which is oriented such that it may receive a shaft or rod of a wire pulling rack. Alternatively, said adapter having a box structure with walls only in two perpendicular planes. At least two of said walls forming a channel extending outwardly that may receive a shaft or rod.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of application Ser. No. 11/375,727,filed Mar. 15, 2006, which claims the benefit of U.S. ProvisionalApplication Ser. No. 60/722,643, filed Sep. 30, 2005.

BACKGROUND OF THE INVENTION

Filamentary materials such as wires, cables and the like are typicallyavailable to electricians or technicians in two forms, on reels orwithin non-reel cartons. The use of reels for the storage,transportation and dispensing of wire or cable is well known in the art.Presently, when electricians wish to dispense wire via a reel, theymight attach the reel to a horizontal shaft of a pulling rack. Forexample, see Floyd U.S. Pat. No. D286,493. An electrician would then beable to pull the wire or cable tangentially off the reel.

However, as an electrician pulls the wire, the entire reel rotates anddevelops momentum. As a result, when the electrician stops pulling, thereel will continue to spin and release wire. The extra wire will oftentangle or kink, requiring the electrician to untangle the wire andrecoil the excess back on to the reel. Another problem with reelpackages is disposal of the empty reel after all the wire has beenremoved.

Non-reel cartons eliminate the need for a reel and the attendant problemof recoiling. These cartons are sometimes also referred to as speed outcartons. Non-reel cartons utilize either conventional cardboard cartonsor specialized cartons with dispensing guides. A single strand, or amulticonductor cable, of material is coiled with an open center (“aircore”) and then placed into the carton. The strand is then dispensedthrough an opening in a wall of the carton. The coil is unwound from thecenter or innermost strand without rotating the entire coil. See WiseU.S. Pat. No. 4,019,636. While non-reel cartons eliminate the unravelingand recoiling problems associated with reels, these cartons have theirown problems. For example, when a coil is unwound from the center of acarton placed on the floor, there can develop enough resistance touncoiling that the entire carton may tend to slide in the direction ofdispensing. This is especially true when the wire is required to makesharp bends as it feeds through a payout tube in the side of the carton.Any tangling of the wire within the carton exacerbates this problem.

Another problem with non-reel cartons has more to do with commonindustry practice than with the carton itself. Many electricians preferto use a portable wire pulling rack on which they can mount severaldifferent sizes, types and colors of wire. This provides ready access towhatever type of wire is needed for a particular job. The pulling rackstypically have one or more shafts on which are mounted reel type wirepackages. Non-reel cartons have no structure that enables them to bemounted on such a rack. If a hole is punched in the non-reel carton toadmit the shaft, there is a risk that doing so will damage the contentsof the carton. Further, even if a shaft hole is successfully formed inthe carton, the carton is not strong enough to support the weight of afull coil of wire on a shaft. Pulling forces would further degrade sucha jury-rigged carton.

Another problem with existing non-reel cartons is the tendency of thecartons to tear at hand-hole openings. Such openings are provided tomake it easy to grasp the carton and carry it. Often users will attemptto use one hand only to lift and carry the carton by the hand-holeopening. Depending on the contents of the carton, this can cause thecarton to fail in the area surrounding the opening. The hand-hole thenbecomes useless and the carton must thereafter be lifted from thebottom, usually using two hands. Hand-hole failure can be a particularproblem if the carton has been allowed to become damp or wet.Accordingly, this invention seeks to overcome these short comings byproviding an adapter for non-reel cartons that allows such cartons to beused on a wire pulling rack.

SUMMARY OF THE INVENTION

The adapter of the present invention is constructed such that it allowsa non-reel carton or container to be hung from a bar, rod or shaft of awire pulling rack with only minor modifications to the carton. Theadapter has a box structure formed by walls or plates that areengageable with at least a single surface of the carton. The boxstructure has walls in two or three perpendicular planes and is adaptedfor placement against the interior top surface of the carton or in acorner of the carton. The box structure mounts a shaft-receiving sleeveor channel. The sleeve or channel defines a passage through which ashaft may be placed. The sleeve or channel transfers gravity and pullingloads to the box structure which in turn spreads these loads over alarge enough surface of the carton that the carton will not be damagedby mounting it on a wire pulling rack.

The adapter may take the form of a variety of shapes or structures. Itmay be manufactured from different materials, including, for example,metal, plastic or fiberglass. The adapter may also contain one or moreapertures or openings, for example, to decrease the amount of materialused in construction of the adapter, to increase the strength of theadapter, or to provide handholds for the combination of the adapter andcarton. The configuration of the walls allows the adapter to be placedinto a carton containing a non-reel coil of filamentary material.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side elevation view of one embodiment of the adapter.

FIG. 2 is a top plan view of the adapter of FIG. 1.

FIG. 3 is a bottom plan view of the adapter.

FIG. 4 is a section taken along line 4-4 of FIG. 2.

FIG. 5 is a perspective view of a non-reel wire carton with its flapsopen on one side to illustrate the adapter of the present inventioninstalled therein.

FIG. 6 is a perspective view of a non-reel wire carton that is ready tobe hung from a shaft, illustrating how the adapter is situated in aclosed carton containing a non-reel coil of filamentary material.

FIG. 7 is a side elevation view of an alternate embodiment of theadapter.

FIG. 8 is a top plan view of the adapter of FIG. 7.

FIG. 9 is a bottom plan view of the alternate embodiment of the adapter.

FIG. 10 is a perspective view of the adapter of FIG. 7.

FIG. 11 is a perspective view of a non-reel wire carton hanging from ashaft that is mounted to a rack.

DETAILED DESCRIPTION OF THE INVENTION

FIGS. 1-4 illustrate the adapter of the present invention generally at1. The adapter has box structure formed by a top plate 2, a back wall 4,and two opposing side walls 10. The top plate 2 has a free edge 8.Opposite the free edge is a right angle corner where the top plate 2connects to the back wall 4. The side walls 10 are generally triangulargussets that join both the top plate 2 and the back wall 4. As seen inFIGS. 1 and 4 the hypotenuse of the gussets may have a curved or archedconfiguration, the curvature of which becomes more pronounced toward theback wall. The top plate and the back and side walls form an open-sided,box structure with surfaces in three mutually perpendicular planes.

Four-sided knobs 12 extend outwardly from the side walls 10. The topedges of the knobs are flush with the upper surface of the top wall.Openings 14 extend fully through the knobs. As explained below, when theadapter 1 is inserted into a carton, the knobs 12 provide a guide andsupport for a rod or shaft to be inserted into the openings 14 andthrough the adapter 1. In this embodiment, the knobs 12 are generallysquare. However, the knobs 12 could have other shapes or they could beplaced in different locations with respect to the top plate and backwalls.

An aperture through the top plate 2 defines a handhold 16. The handhold16 is designed to be comfortable to grip and to carry the combination ofthe adapter 1 and a carton.

The underside 6 of top plate 2 has two depending walls or ribs 13 and15. Ribs 13 and 15, together with the portion of the top plate 2 betweenthem and the knobs 12, define a shaft-receiving sleeve. A passageway orchannel 17 is defined by the ribs 13, 15 and the portion of the topplate 2 between the ribs. Channel 17 aligns with openings 14 in theknobs 12. The passageway 17 extends from one side wall 10 to the otherside wall 10. The openings 14 and the channel or passageway 17 allow abar, dowel, shaft, or rod (not shown) to be passed through the adapter 1such that the adapter 1 may be hung from a pulling rack on the bar,dowel, shaft, or rod. The openings 14 and the passageway 17 may havedifferent configurations to receive different shapes or sizes of rods orshafts. That is, while the openings 14 are shown with a circular crosssection, the cross section could be non-circular to provide ananti-rotation feature. Also, while the channel 17 is shown open to thebottom, the fourth side of the channel may also be enclosed to fullyshield a rod or shaft inserted therein.

FIG. 5 illustrates the adapter in preparation for use. The adapter 1 isinserted into a corner of a carton 22 containing a non-reel or “aircore” coil of filamentary material 28 such as wire or cable. Typically,these cartons 22 or containers are constructed using cardboard orsimilar materials. As a result, the configuration of the adapter 1 isdesigned to reinforce or provide structural support for the carton, suchthat when the carton is hung utilizing the adapter 1, gravity andpulling loads on the carton 22 are spread out over a large surface area.By spreading out these loads, the adapter 1 reduces the possibility ofthe carton tearing or otherwise failing. The knobs 12 extend outwardly,through cutouts 23 in the carton 22, and slightly beyond the exteriorsurfaces of the carton 22. The engagement of the protruding knobs 12with the cutouts 23 locks the adapter in place in the carton. The knobsalso serve as spacers between adjacent cartons or reels on a pullingrack. It sometimes happens that a non-reel carton is placed on a racknext to a spool or reel. Rotation of the reel can potentially damage thecardboard carton of the non-reel container. The knobs absorb suchcontact and prevent the cardboard carton from being damaged by adjacentreels.

As shown in FIG. 5, an inner strand 26 of the non-reel coil 28 is paidout from the innermost coil 30 through the body of the coil and out theside of the carton 22 by way of a payout tube 24. The payout tube 24 ismounted in a side wall of the carton. The design and placement of theadapter 1 does not interfere with the paying out of the coil 28.

FIG. 6 shows the top of a closed carton 22 in what might be considered anormal, upright position. In this position, the adapter 1 sits in anupper corner above the payout tube 24. The knobs 12 of the adapter 1extend outside of the closed carton 22. To hang the carton 22 from apulling rack, a shaft of the pulling rack would be inserted into theopening 14 in one of the knobs 12, through the channel 17 and out theopposite opening 14. The ends of the shaft are then secured in the rack.As can be seen through the handhold 16, the non-reel coil 28 sits in thecarton 22 in a vertical position. The strand 26 of filamentary materialfrom the coil 28 is paid out through payout tube 24 in the side of thecarton. Note also that the handhold 16 aligns with an opening in thecarton 22. This allows the carton to be conveniently grasped at thehandhold and carried without risk of tearing or damaging the carton,even if the carton is wet.

The adapter is preferably installed in a corner of the carton, althoughit could be otherwise. Placement of the adapter in a corner allows thecarton to hang on a shaft at an angle so that gravity and pulling loadsare spread on to two perpendicular walls. The adapter has a simple,one-piece construction that is quick and easy to install. By convertinga non-reel carton for use with a pulling rack, a wire supplier canreduce the amount of inventory formerly needed for different types ofpackages. The adapter allows a non-reel carton to provide the benefitsof a reel while avoiding its disadvantages.

The adapter may have an alternate box structure that allows the adapterto fit inside a carton or container. As shown in FIGS. 7-10, instead ofhaving walls in three planes, it could be that the adapter walls onlydefine two planes.

FIGS. 7-10 illustrate an alternative embodiment of the adapter of thepresent invention generally at 31. The adapter 31 has a box structure,with walls or surfaces in two perpendicular planes. The box structure isformed by a top plate 32, a stiffening wall 34, a front rib 36 and aninterior rib 38. The front rib 36, the interior rib 38 and a portion ofthe top plate 32 define a passageway or channel 40.

An opening 42 through the top plate 32 defines a handhold. The handhold42 is designed to be comfortable to grip and to carry the combination ofthe adapter 31 and a carton. Typically, non-reel cartons containingfilamentary material have an opening for a handhold at the top of thecarton. The handhold 42 aligns with this opening in the top of thecarton. An electrician or other user of these cartons accesses thishandhold by pushing into the carton one or more partially perforatedflaps. The perforated flaps of the carton will pass through the handholdopening 42 of the top plate 32 and further aid in securing the adapterto the interior of a carton. This also allows the carton to beconveniently grasped at the handhold and carried without risk of tearingor damaging the carton, even if the carton is wet.

Several other smaller openings 44, may be added to the top plate toreduce the amount of material required to manufacture the adapter 31.Similarly, optional grooves 46 along the trailing edge 48, leading edge49, and the top plate 32 may be added to further reduce the materialrequire to manufacture the adapter 31. The grooves 46 may also furtheraid in securing the adapter within the carton.

The underside 50 of the top plate 32 has three depending structures, afront rib 36 and interior rib 38 and a stiffening wall 34. Ribs 36 and38 together with a portion of the underside 50 of the top plate 32define a shaft-receiving channel or passageway 40. The passageway 40extends outwardly past the sides of the top plate 32. The channel orpassageway 40 allows a bar, dowel, shaft, or rod (not shown) to bepassed through the adapter 31 such that the adapter 31 may be hung froma pulling rack on the bar, dowel, shaft, or rod. While the channel 40 isshown open to the bottom, the fourth side of the channel may also beenclosed to fully or partially shield a rod or shaft inserted therein.

Along the trailing edge 48 is a right angle corner where the top plate32 connects with the stiffening wall 34. The stiffening wall 34 may havenumerous configurations and may contain openings 52 of various sizes andshapes. The openings may be added to reduce the amount of materialneeded to manufacture the adapter 31.

Similarly, the front rib 36 and interior rib 38 may have numerousconfigurations and shapes. As shown in FIG. 10, the front rib 36 andinterior rib 38 may be formed by two opposing trapezoidal extensions 54,55 located adjacent to either side of the top plate 32. A ridge 56connects the trapezoidal extensions 54, 55. The trapezoidal extensionsmay have openings or apertures, for example, to decrease the amount ofmaterial used in construction of the adapter or to provide handholds forboth the adapter and the carton. It is not necessary for the front rib36 and interior rib 38 to have the same configuration.

The adapter 31 is installed within carton against the interior topsurface of the carton. Placement of the adapter 31 along the top of thecarton allows the carton to hang on a shaft at an angle so that gravityand pulling loads are spread along the top surface or wall of thecarton. The adapter has a simple, one-piece construction that is quickand easy to install. By converting a non-reel carton for use with apulling rack, a wire supplier can reduce the amount of inventoryformerly needed for different types of packages. The adapter allows anon-reel carton to provide the benefits of a reel while avoiding itsdisadvantages.

The first embodiment of the adapter 1 and second embodiment of theadapter 31 may have other configurations and structures. For example,the back wall of first embodiment of the adapter 1 may be deleted. Inthis case, it may be desirable to have the ends of the side walls buttup against an end wall of the carton. Alternately, the two-sided boxstructure could be located remote from an end wall of the carton. In anycase, the box structure must be designed to fit around a non-reel coilof filamentary material (wire, cable, etc.) enclosed within a carton. Inanother alternate embodiment, the back wall 4 of the first embodiment ofthe adapter 1 could be extended from that shown so a payout openingcould be formed in the wall.

The first embodiment of the adapter 1 and second embodiment of theadapter 31 may also contain additional apertures or openings, forexample, to decrease the amount of material used in construction of theadapter or to provide handholds for both the adapter and the carton.Accordingly, while the top plate and side walls are shown as largelycontinuous surfaces of the first embodiment of the adapter 1, it couldbe otherwise so long as the top plate prevents concentration of loadsbetween the shaft and the carton. It may also be manufactured fromdifferent materials.

We claim:
 1. A method of hanging a carton containing contents on a rack,comprising the steps of: inserting an adapter having a passageway forreceiving a shaft into a carton, the carton having a top panel and theadapter having a top plate which, upon insertion of the adapter into thecarton, is parallel to and in engagement with the top panel; inserting ashaft through the carton and through said passageway; and mounting theshaft on a rack with the gravity load of the contents bearing on thecarton and being transferred to the shaft through the top panel of thecarton and the top plate of the adapter.
 2. An article for dispensingfilamentary material, comprising: a carton including a top panel havingan interior surface and opposite side edges, the carton furtherincluding a side panel joined to each of the side edges of the toppanel, the top and side panels defining an interior and exterior of thecarton, each side panel having a cutout therein with the cutouts atleast partially aligned with one another; and an adapter disposed in theinterior of the carton, the adapter having a top plate parallel to andin engagement with the interior surface of the carton's top panel, thetop plate of the adapter being disposed adjacent the cutouts such thatthe top plate is engageable with a shaft inserted from the exterior ofthe carton through the cutouts, the gravity load of the filamentarymaterial bearing on the carton and being transferred to the insertedshaft through the top panel of the carton and the top plate of theadapter.
 3. The article for dispensing filamentary material of claim 2wherein the adapter further comprises a wall attached to the top plateand extending out of the plane thereof.
 4. An adapter for a cartoncomprising: a top plate engageable with a surface of the carton on theinterior thereof, at least a portion of the top plate being engageablewith a shaft inserted from the exterior of the carton through thecarton, the top plate spreading the load of the shaft onto the surfaceof the carton; and a handhold in the top plate.
 5. The adapter of claim4 wherein the adapter further comprises a wall attached to the top plateand extending out of the plane thereof.
 6. An adapter for a cartoncontaining contents comprising: a planar top plate engageable with asurface of the carton on the interior thereof, at least a portion of thetop plate being engageable with a shaft inserted from the exterior ofthe carton through the carton, the gravity load of the contents bearingon the carton and being transferred to the inserted shaft through thetop panel of the carton and the top plate; and at least one extensionextending from the top plate and engageable with the carton.
 7. Theadapter of claim 6 wherein the adapter further comprises a wall attachedto the top plate and extending out of the plane thereof.